Total Cost of Operations TCO
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1 Total Cost of Operations TCO
2 Agenda Introduction Objectives Elements of TCO ABC Costing TCO in a working Fab Fab Cost Product Margin Building TCO Model Summary
3 Introduction Total Cost of Operations is a methodology that regards planning as the blueprint for an organization s operation and more then a mean to calculate immediate expansion and capital tool costs. Spending money wisely should not only provide a lower project cost for any expansion but also the most cost effective fab in the long run As a proactive process, TCO uses mathematical, and statistical tools to compensate for market uncertainties. Its strength is built on a process step understanding of each possible product mix. Showing the different capacity requirements for each product together with the cost and margin lets us select the best product mix for our line.
4 Objectives To perform long term planning in an uncertain market, creating the ability to understand different market scenarios and create operational plan to cover all of them with the minimal tool purchase. Capitalizing on TCO as one of the keys to survivals and success for a semiconductors manufacturing company. Understanding TCO allows you to make the most out of your line. Using smart planning coupled with detailed resources and cost understanding as the base for operational excellence. History teaches us that in many cases companies with the superior technology were defeated by more efficient organizations.
5 Elements of TCO Facility and infrastructure costs Direct vs. Indirect Fixed vs. variable Equipment purchase and maintenance Process Tools Metrology tool Material costs Human resources Tool Operators Equipment technicians Support Engineers Admin support staff Indirect labor costs
6 ABC Costing ABC Total Cost per product by Area 100.0% Activity Based Cost Modeling 90.0% 80.0% 70.0% 60.0% 50.0% Cost driver Process Step Product A 40.0% 30.0% 20.0% 10.0% 0.0% Product A Product B Product C Die Vis 291, , ,460 Backside 1,697, , ,805 DC Test 247, ,220 90,049 RF Test 324, , ,368 Metals 2,061,522 1,377, ,676 Etch 1,525, , ,151 Optical 1,520, , ,702 E-Beam 585, ,220 90,049 Materials 1,053, ,220 90,049
7 TCO In a Working Fab To implement TCO in a real manufacturing environment, a very detailed understanding of all processes and resources is needed. MAX TCO model drills down to the step level to associate all direct costs related to that step including capacity requirements and fab loading requirements. Even when no expansions are considered TCO lets you optimize the line by loading it with the most profitable products, based on real life cost and capacity requirements data.
8 Fab Cost Analysis Simulation Period = Technology A Shift Structure Simulation Value 200 Technology B # of Shifts per day Technology C Hrs Per Shift Technology D Total no of shifts Technology E # of Work Days Technology F Total Hrs per Month Technology G Area Summary Operator / Tech Availability 85.0% Required Floor Space Purchase Cost Instalation Cost Total Cost Operator / Tech Workload 87.5% (Sq. Ft) (K$) (K$) Operators Required/Shift 10 PHOTO , ,251 Total # of Operators 40 ETCH 1, , ,460 Techs Required/Shift 7 METALS , ,605 Total # of Techs 28 PECVD , ,055 CMP , ,600 METROLOGY , ,060 BACKSIDE , ,105 DIE SORT , ,415 Total Fab 4,071 20,355 2,196 22,551 Corridor Space 611 Gown Room Space 611 Squareness Factor 407 Gross Total Space 5,
9 Product Margin Analysis Simulation Period = 2005 As can be seen from table TCO model gives us the capacity requirements for each technology or product as well as cost and margin. Letting us optimize fab loading for profit and not just throughput Load Technology Cap % 600 Technology A 15% 200 Technology B 15% 400 Technology C 13% 300 Technology D 10% 560 Technology E 10% 200 Technology F 18% 240 Technology G 19% 2500 Total Line Load 100% Cost / Wafer Note cost and data figures were removed due to data sensitivity issues. Margin
10 Graphical Trends As can be seen in the next examples TCO lets us understand different alternatives along a ramp and time line $K 48,000 44,000 40,000 36,000 32,000 28,000 24,000 20,000 16,000 12,000 8,000 4,000 - TCO Cum Inv. Cost / Volume Wafer Volume (4" Equiv.) 6" Conversion 4" Production Note above graph shows 4 Vs 6 conversion
11 Graphical cont TCO Cum Investment Cost and Demand Profile $K 45,000 40,000 35,000 30,000 25,000 20,000 15,000 10,000 5,000-3,500 3,000 2,500 2,000 1,500 1, Year 6" Conversion 4" Production Demand Profile Volume (4" Equiv.) TCO Cost / Unit by Volume Ce nts/unit Volume (4" equivalents) 6" Conversion 4" Production
12 Building the Model MAX I.E.G. has developed the TCO model in two formats, a visual basic SQL DB application, or an excel spreadsheet application. Both solutions are custom tailored to a specific fab on implementation. The process of collecting the data and customizing the models to a specific fab is one of the reasons for its accuracy. Typical implementation is between 4 to 8 weeks.
13 Meeting the Needs Our industry has a cyclical nature, thus making sure that you optimize your resources, in a manner that allows you to get the most margin without frivolous purchases is a distinct competitive advantage. TCO builds profit from operational knowledge. Profit Optimization Fab Wide Capacity Process Flows Tool Speed Modeling
14 Our Strengths Starting with a detailed understanding of each process step on each product. Assigning steps to tools and building speed and capacity models Creating a fab wide capacity and costs model to understand Total Cost of Operations. TCO
15 Key Benefits Implementing MAX s TCO will allow the organization to optimize the current line for maximum profit. Future expansions will be performed with the understanding of not only the expansion project cost, but also the true meaning of each scenario in profit terms. Minimizing tool investments by making the most out of the line also means less idle tools in the downturns to come.
16 Summary Each semiconductors fab is as unique as its toolset and product mix. A true modeling tool must be able to capture the uniqueness of each fab while still maintaining a solid modeling engine and ease of implementation. MAX TCO is the only turnkey solution to fab modeling designed by fab people and implemented by fab people.
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